Filter loading

ABSTRACT

A pumping system for moving water of a swimming pool includes a water pump, a variable speed motor, and a filter arrangement in fluid communication with the pump. The pumping system can also include means for determining a load value indicative of an unclogged filter that permits movement of water through the filter arrangement, means for determining a load value indicative of a clogged filter that inhibits movement of water through the filter arrangement, and means for determining a performance value of the pumping system. The pumping system also includes means for determining a relative loading value of the filter arrangement, means for displaying the relative loading value, and means for controlling the motor in response to the relative loading value. In one example, the load values and performance value can include flow pressure values. A method of moving water of a swimming pool is also disclosed.

RELATED APPLICATIONS

This application is a continuation-in-part application of U.S.application Ser. No. 10/926,513, filed Aug. 26, 2004, and U.S.application Ser. No. 11/286,888, filed Nov. 23, 2005, the entiredisclosures of which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to control of a pump, and moreparticularly to control of a variable speed pumping system for a pool.

BACKGROUND OF THE INVENTION

Conventionally, a pump to be used in a pool is operable at a finitenumber of predetermined speed settings (e.g., typically high and lowsettings). Typically these speed settings correspond to the range ofpumping demands of the pool at the time of installation. Factors such asthe volumetric flow rate of water to be pumped, the total head pressurerequired to adequately pump the volume of water, and other operationalparameters determine the size of the pump and the proper speed settingsfor pump operation. Once the pump is installed, the speed settingstypically are not readily changed to accommodate changes in the poolconditions and/or pumping demands.

Conventionally, it is also typical to equip a pumping system for use ina pool with a filter arrangement capable of filtering the fluid moved bythe pumping system, such as water. The filter arrangement can filter thefluid to remove unwanted impurities and particulates therefrom tomaintain the water clarity and chemical balance. However, during use, itis possible that the filter arrangement can become clogged over time soas to inhibit the flow of the water therethrough. Thus, resistance tothe flow of water can cause a decrease in the flow rate if the pumpingsystem does not compensate to overcome this resistance. However, merelyadjusting the pump to one of a few predetermined settings may cause thepump to operate at a rate that exceeds a needed rate, while adjustingthe pump to another setting may cause the pump to operate at a rate thatprovides an insufficient amount of flow and/or pressure. In such a case,the pump will either operate inefficiently or operate at a level belowthat which is desired.

Accordingly, it would be beneficial to provide a pump that could bereadily and easily adapted to provide a suitable supply of water at adesired pressure to pools having a variety of sizes and features. Thepumping system can be configured to monitor the status of the filterarrangement and provide feedback to a user regarding the filter status.Further, the pump should be responsive to a change of conditions (i.e.,a clogged filter or the like) and/or user input instructions.

SUMMARY OF THE INVENTION

In accordance with one aspect, the present invention provides a pumpingsystem for moving water of a swimming pool. The pumping system includesa water pump for moving water in connection with performance of afiltering operation upon the water, a variable speed motor operativelyconnected to drive the pump, and a filter arrangement in fluidcommunication with the pump. The pumping system also includes means fordetermining a load value indicative of an unclogged filter that permitsmovement of water through the filter arrangement, means for determininga load value indicative of a clogged filter that inhibits movement ofwater through the filter arrangement, and means for determining aperformance value of the pumping system. The pumping system alsoincludes means for determining a relative loading value of the filterarrangement based upon the load value indicative of an unclogged filter,load value indicative of a clogged filter, and the performance value.The pumping system also includes means for displaying the relativeloading value, and means for controlling the motor in response to therelative loading value.

In accordance with another aspect, the present invention provides apumping system for moving water of a swimming pool. The pumping systemincludes a water pump for moving water in connection with performance ofa filtering operation upon the water, a variable speed motor operativelyconnected to drive the pump, and a filter arrangement in fluidcommunication with the pump. The pumping system also includes means fordetermining a flow pressure value indicative of an unclogged filter thatpermits movement of water through the filter arrangement, means fordetermining a threshold flow pressure value indicative of a cloggedfilter that inhibits movement of water through the filter arrangementand means for determining an actual pressure value of the pumping systemduring the filtering operation. The pumping system also includes meansfor determining a relative loading value of the filter arrangement basedupon the pressure value indicative of an unclogged filter, thresholdpressure value indicative of a clogged filter, and the actual pressurevalue, and means for displaying the relative loading value as apercentage with respect to the threshold flow pressure value.

In accordance with another aspect, the present invention provides apumping system for moving water of a swimming pool. The pumping systemincludes a water pump for moving water in connection with performance ofa filtering operation upon the water, a variable speed motor operativelyconnected to drive the pump, and a filter arrangement in fluidcommunication with the pump. The pumping system also includes means fordetermining a flow pressure value indicative of an unclogged filter thatpermits movement of water through the filter arrangement, means fordetermining a threshold flow pressure value indicative of a cloggedfilter that inhibits movement of water through the filter arrangement,and means for determining an actual pressure value of the pumping systemduring the filtering operation. The pumping system also includes meansfor determining a relative loading value of the filter arrangement basedupon the pressure value indicative of an unclogged filter, pressurevalue indicative of a clogged filter, and the actual pressure value, andmeans for controlling the motor to perform an operation upon the water.The means for controlling is configured to alter operation of the motorwhen the relative loading value exceeds a predetermined value.

In accordance with yet another aspect, the present invention provides amethod of moving water of a swimming pool including a water pump formoving water in connection with performance of a filtering operationupon the water, a variable speed motor operatively connected to drivethe pump, and a filter arrangement in fluid communication with the pump.The method comprises the steps of determining a flow pressure valueindicative of an unclogged filter that permits movement of water throughthe filter arrangement, determining a threshold flow pressure valueindicative of a clogged filter that inhibits movement of water throughthe filter arrangement, and determining an actual pressure value of thepumping system during the filtering operation. The method also includesthe steps of determining a relative loading value of the filterarrangement based upon the pressure value indicative of an uncloggedfilter, pressure value indicative of a clogged filter, and the actualpressure value, displaying the relative loading value, and controllingthe motor in response to the relative loading value.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the present inventionwill become apparent to those skilled in the art to which the presentinvention relates upon reading the following description with referenceto the accompanying drawings, in which:

FIG. 1 is a block diagram of an example of a variable speed pumpingsystem in a pool environment in accordance with the present invention;

FIG. 2 is another block diagram of another example of a variable speedpumping system in a pool environment in accordance with the presentinvention;

FIG. 3 is a diagram of an example filter loading profile for a filterarrangement between an unclogged condition and a clogged condition;

FIG. 4 is a function flow chart for an example methodology in accordancewith the present invention;

FIG. 5 is a perceptive view of an example pump unit that incorporatesone aspect of the present invention;

FIG. 6 is a perspective, partially exploded view of a pump of the unitshown in FIG. 5; and

FIG. 7 is a perspective view of a controller unit of the pump unit shownin FIG. 5.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Certain terminology is used herein for convenience only and is not to betaken as a limitation on the present invention. Further, in thedrawings, the same reference numerals are employed for designating thesame elements throughout the figures, and in order to clearly andconcisely illustrate the present invention, certain features may beshown in somewhat schematic form.

An example variable-speed pumping system 10 in accordance with oneaspect of the present invention is schematically shown in FIG. 1. Thepumping system 10 includes a pump unit 12 that is shown as being usedwith a pool 14. It is to be appreciated that the pump unit 12 includes apump 16 for moving water through inlet and outlet lines 18 and 20.

The swimming pool 14 is one example of a pool. The definition of“swimming pool” includes, but is not limited to, swimming pools, spas,and whirlpool baths. Features and accessories may be associatedtherewith, such as water jets, waterfalls, fountains, pool filtrationequipment, chemical treatment equipment, pool vacuums, spillways and thelike.

A water operation 22 is performed upon the water moved by the pump 16.Within the shown example, the water operation 22 is a filter arrangementthat is associated with the pumping system 10 and the pool 14 forproviding a cleaning operation (i.e., filtering) on the water within thepool. The filter arrangement 22 is operatively connected between thepool 14 and the pump 16 at/along an inlet line 18 for the pump. Thus,the pump 16, the pool 14, the filter arrangement 22, and theinterconnecting lines 18 and 20 form a fluid circuit or pathway for themovement of water.

It is to be appreciated that the function of filtering is but oneexample of an operation that can be performed upon the water. Otheroperations that can be performed upon the water may be simplistic,complex or diverse. For example, the operation performed on the watermay merely be just movement of the water by the pumping system (e.g.,re-circulation of the water in a waterfall or spa environment).

Turning to the filter arrangement 22, any suitable construction andconfiguration of the filter arrangement is possible. For example, thefilter arrangement 22 can include a sand filter, a cartridge filter,and/or a diatomaceous earth filter, or the like. In another example, thefilter arrangement 22 may include a skimmer assembly for collectingcoarse debris from water being withdrawn from the pool, and one or morefilter components for straining finer material from the water. In stillyet another example, the filter arrangement 22 can be in fluidcommunication with a pool cleaner, such as a vacuum pool cleaner adaptedto vacuum debris from the various submerged surfaces of the pool. Thepool cleaner can include various types, such as various manual and/orautomatic types.

The pump 16 may have any suitable construction and/or configuration forproviding the desired force to the water and move the water. In oneexample, the pump 16 is a common centrifugal pump of the type known tohave impellers extending radially from a central axis. Vanes defined bythe impellers create interior passages through which the water passes asthe impellers are rotated. Rotating the impellers about the central axisimparts a centrifugal force on water therein, and thus imparts the forceflow to the water. Although centrifugal pumps are well suited to pump alarge volume of water at a continuous rate, other motor-operated pumpsmay also be used within the scope of the present invention.

Drive force is provided to the pump 16 via a pump motor 24. In the oneexample, the drive force is in the form of rotational force provided torotate the impeller of the pump 16. In one specific embodiment, the pumpmotor 24 is a permanent magnet motor. In another specific embodiment,the pump motor 24 is an induction motor. In yet another embodiment, thepump motor 24 can be a synchronous or asynchronous motor. The pump motor24 operation is infinitely variable within a range of operation (i.e.,zero to maximum operation). In one specific example, the operation isindicated by the RPM of the rotational force provided to rotate theimpeller of the pump 16. In the case of a synchronous motor 24, thesteady state speed (RPM) of the motor 24 can be referred to as thesynchronous speed. Further, in the case of a synchronous motor 24, thesteady state speed of the motor 24 can also be determined based upon theoperating frequency in hertz (Hz). Thus, either or both of the pump 16and/or the motor 24 can be configured to consume power during operation.

A controller 30 provides for the control of the pump motor 24 and thusthe control of the pump 16. Within the shown example, the controller 30includes a variable speed drive 32 that provides for the infinitelyvariable control of the pump motor 24 (i.e., varies the speed of thepump motor). By way of example, within the operation of the variablespeed drive 32, a single phase AC current from a source power supply isconverted (e.g., broken) into a three-phase AC current. Any suitabletechnique and associated construction/configuration may be used toprovide the three-phase AC current. The variable speed drive suppliesthe AC electric power at a changeable frequency to the pump motor todrive the pump motor. The construction and/or configuration of the pump16, the pump motor 24, the controller 30 as a whole, and the variablespeed drive 32 as a portion of the controller 30, are not limitations onthe present invention. In one possibility, the pump 16 and the pumpmotor 24 are disposed within a single housing to form a single unit, andthe controller 30 with the variable speed drive 32 are disposed withinanother single housing to form another single unit. In anotherpossibility, these components are disposed within a single housing toform a single unit. Further still, the controller 30 can receive inputfrom a user interface 31 that can be operatively connected to thecontroller in various manners.

The pumping system 10 has means used for control of the operation of thepump. In accordance with one aspect of the present invention, thepumping system 10 includes means for sensing, determining, or the likeone or more parameters indicative of the operation performed upon thewater. Within one specific example, the system includes means forsensing, determining or the like one or more parameters indicative ofthe movement of water within the fluid circuit.

The ability to sense, determine or the like one or more parameters maytake a variety of forms. For example, one or more sensors 34 may beutilized. Such one or more sensors 34 can be referred to as a sensorarrangement. The sensor arrangement 34 of the pumping system 10 wouldsense one or more parameters indicative of the operation performed uponthe water. Within one specific example, the sensor arrangement 34 sensesparameters indicative of the movement of water within the fluid circuit.The movement along the fluid circuit includes movement of water throughthe filter arrangement 22. As such, the sensor arrangement 34 includesat least one sensor used to determine flow rate of the water movingwithin the fluid circuit and/or includes at least one sensor used todetermine flow pressure of the water moving within the fluid circuit. Inone example, the sensor arrangement 34 is operatively connected with thewater circuit at/adjacent to the location of the filter arrangement 22.It should be appreciated that the sensors of the sensor arrangement 34may be at different locations than the locations presented for theexample. Also, the sensors of the sensor arrangement 34 may be atdifferent locations from each other. Still further, the sensors may beconfigured such that different sensor portions are at differentlocations within the fluid circuit. Such a sensor arrangement 34 wouldbe operatively connected 36 to the controller 30 to provide the sensoryinformation thereto.

It is to be noted that the sensor arrangement 34 may accomplish thesensing task via various methodologies, and/or different and/oradditional sensors may be provided within the system 10 and informationprovided therefrom may be utilized within the system. For example, thesensor arrangement 34 may be provided that is associated with the filterarrangement and that senses an operation characteristic associated withthe filter arrangement. For example, such a sensor may monitor filterperformance. Such monitoring may be as basic as monitoring filter flowrate, filter pressure, or some other parameter that indicatesperformance of the filter arrangement. Of course, it is to beappreciated that the sensed parameter of operation may be otherwiseassociated with the operation performed upon the water. As such, thesensed parameter of operation can be as simplistic as a flow indicativeparameter such as rate, pressure, etc.

Such indication information can be used by the controller 30, viaperformance of a program, algorithm or the like, to perform variousfunctions, and examples of such are set forth below. Also, it is to beappreciated that additional functions and features may be separate orcombined, and that sensor information may be obtained by one or moresensors.

With regard to the specific example of monitoring flow rate and flowpressure, the information from the sensor arrangement 34 can be used asan indication of impediment or hindrance via obstruction or condition,whether physical, chemical, or mechanical in nature, that interfereswith the flow of water from the pool to the pump such as debrisaccumulation or the lack of accumulation, within the filter arrangement34. As such, the monitored information can be indicative of thecondition of the filter arrangement.

The example of FIG. 1 shows an example additional operation 38 and theexample of FIG. 2 shows an example additional operation 138. Such anadditional operation (e.g., 38 or 138) may be a cleaner device, eithermanual or autonomous. As can be appreciated, an additional operationinvolves additional water movement. Also, within the presented examplesof FIGS. 1 and 2, the water movement is through the filter arrangement(e.g., 22 or 122). Such additional water movement may be used tosupplant the need for other water movement.

Within another example (FIG. 2) of a pumping system 110 that includesmeans for sensing, determining, or the like one or more parametersindicative of the operation performed upon the water, the controller 130can determine the one or more parameters via sensing, determining or thelike parameters associated with the operation of a pump 116 of a pumpunit 112. Such an approach is based upon an understanding that the pumpoperation itself has one or more relationships to the operationperformed upon the water.

It should be appreciated that the pump unit 112, which includes the pump116 and a pump motor 124, a pool 114, a filter arrangement 122, andinterconnecting lines 118 and 120, may be identical or different fromthe corresponding items within the example of FIG. 1. In addition, asstated above, the controller 130 can receive input from a user interface131 that can be operatively connected to the controller in variousmanners.

Turning back to the example of FIG. 2, some examples of the pumpingsystem 110, and specifically the controller 130 and associated portions,that utilize at least one relationship between the pump operation andthe operation performed upon the water attention are shown in U.S. Pat.No. 6,354,805, to Moller, entitled “Method For Regulating A DeliveryVariable Of A Pump” and U.S. Pat. No. 6,468,042, to Moller, entitled“Method For Regulating A Delivery Variable Of A Pump.” The disclosuresof these patents are incorporated herein by reference. In short summary,direct sensing of the pressure and/or flow rate of the water is notperformed, but instead one or more sensed or determined parametersassociated with pump operation are utilized as an indication of pumpperformance. One example of such a pump parameter is input power.Pressure and/or flow rate can be calculated/determined from such pumpparameter(s).

Although the system 110 and the controller 130 there may be of variedconstruction, configuration and operation, the function block diagram ofFIG. 2 is generally representative. Within the shown example, anadjusting element 140 is operatively connected to the pump motor and isalso operatively connected to a control element 142 within thecontroller 130. The control element 142 operates in response to acomparative function 144, which receives input from a power calculation146.

The power calculation 146 is performed utilizing information from theoperation of the pump motor 124 and controlled by the adjusting element140. As such, a feedback iteration is performed to control the pumpmotor 124. Also, it is the operation of the pump motor and the pump thatprovides the information used to control the pump motor/pump. Asmentioned, it is an understanding that operation of the pump motor/pumphas a relationship to the flow rate and/or pressure of the water flowthat is utilized to control flow rate and/or flow pressure via controlof the pump.

As mentioned, the sensed, determined (e.g., calculated, provided via alook-up table, graph or curve, such as a constant flow curve or thelike, etc.) information can be utilized to determine the variousperformance characteristics of the pumping system 110, such as inputpower consumed, motor speed, flow rate and/or the flow pressure. In oneexample, the operation can be configured to prevent damage to a user orto the pumping system 10, 110 caused by an obstruction. Thus, thecontroller (e.g., 30 or 130) provides the control to operate the pumpmotor/pump accordingly. In other words, the controller (e.g., 30 or 130)can repeatedly monitor one or more performance value(s) 146 of thepumping system 10,110, such as the input power consumed by, or the speedof, the pump motor (e.g., 24 or 124) to sense or determine a parameterindicative of an obstruction or the like.

Turning to the issue of operation of the system (e.g., 10 or 110) over acourse of a long period of time, it is typical that a predeterminedvolume of water flow is desired. For example, it may be desirable tomove a volume of water equal to the volume within the pool. Suchmovement of water is typically referred to as a turnover. It may bedesirable to move a volume of water equal to multiple turnovers within aspecified time period (e.g., a day). Within an example in which thewater operation includes a filter operation, the desired water movement(e.g., specific number of turnovers within one day) may be related tothe necessity to maintain a desired water clarity.

Within the water operation that contains a filter operation, the amountof water that can be moved and/or the ease by which the water can bemoved is dependent in part upon the current state (e.g., quality,cleanliness) of the filter arrangement. In general, a clean (e.g., new,fresh, backwashed) filter arrangement provides a lesser impediment towater flow than a filter arrangement that has accumulated filter matter(e.g., dirty). For a constant flow rate through a filter arrangement, alesser pressure is required to move the water through a clean filterarrangement than a pressure that is required to move the water through adirty filter arrangement. Another way of considering the effect of dirtaccumulation is that if pressure is kept constant then the flow ratewill decrease as the dirt accumulates and hinders (e.g., progressivelyblocks) the flow.

Turning to one aspect that is provided by the present invention, thesystem can operate to maintain a constant flow of water within the fluidcircuit. Maintenance of constant flow is useful in the example thatincludes a filter arrangement. Moreover, the ability to maintain aconstant flow is useful when it is desirable to achieve a specific flowvolume during a specific period of time. For example, it may bedesirable to filter pool water and achieve a specific number of waterturnovers within each day of operation to maintain a desired waterclarity despite the fact that the filter arrangement will progressivelyincrease dirt accumulation.

It should be appreciated that maintenance of a constant flow volumedespite an increasing impediment caused by filter dirt accumulation canrequire an increasing pressure and is the result of increasing motiveforce from the pump/motor. As such, one aspect of the present inventionis to control the motor/pump to provide the increased motive force thatprovides the increased pressure to maintain the constant flow.

Turning to one specific example, attention is directed to the filterloading chart 200 that is shown in FIG. 3. The filter loading chart 200shows a relationship between a relative filter loading value 202 and anassociated performance value 204 of the filter arrangement, such aspressure. For example, when the filter arrangement is substantiallyclean, such as when it is new or after a cleaning operation (e.g., abackwash cycle), the relative filter loading value 206 of the filterarrangement can be approximately 0%. Correspondingly, the associatedperformance value 208 can indicate an initial or unclogged pressurevalue (OP) within the filter arrangement at a specific water flow rate.Similarly, when the filter arrangement (e.g., filter, skimmer, poolcleaner, etc.) is substantially dirty and/or clogged, such as after canoccur over a period of time, the relative filter loading value 210 canbe approximately 100%, while a corresponding performance value 212 canindicate a final or clogged pressure value (CFP) within the filterarrangement at substantially the same water flow rate. Thus, as can beseen from the chart 200, as the filter loading 202 changes (e.g.,increases), the associated performance value 204 can also change (e.g.,increase), and a relationship can be determined therebetween. In oneexample, a mathematical relationship can be determined to permit therelative filter loading value 202 to be calculated, or predetermineddata can also be collected to permit the relative filter loading value202 to be determined from a look-up table or the like. For example, asshown, if a performance value 214 (AP) can be determined (e.g., directlyor indirectly measured) during the filtration operation, a correspondingfilter loading 204 can also be determined (e.g., calculated, look-uptable, etc.).

It is to be appreciated that various relationships can be determinedbetween the relative loading value 202 and the performance value 204,and that various performance values 204 can be used (e.g., motor speed,power consumption of the pump unit 12,112 and/or motor 24, 124, flowrate and/or flow pressure of water moved by the pump unit 12, 112, orthe like). It is also to be appreciated that although the chart 200shows an example linear relationship between the relative filter loadingvalue 202 and the performance value 204, various other relationships(e.g., polynomial equation, exponential equation, or the like) can alsobe used.

Turning now to one specific example of a filter loading control system,attention is directed to the block diagram of FIG. 4 that shows anexample control system. It is to be appreciated that the block diagramas shown is intended to be only one example method of operation, andthat more or less elements can be included in various orders. For thesake of clarity, the example block diagram described below can controlthe flow of the pumping system based on a detection of a performancevalue, such as a change in flow pressure and/or filter loading asdetermined though either direct or indirect measurement and/ordetermination. Thus, in one example, the flow rate of water through thefluid circuit can be controlled upon a determination of a change in flowpressure. In a “sensorless” system, the flow pressure can be determineddirectly or indirectly from a measurement of various other values. Inone example, the flow pressure can be determined from a measurement ofmotor speed and flow rate of the pumping system 10, 110. Thus, thecontroller 30, 130 can contain a one or more predetermined pump curvesor associated tables using various variables (e.g., motor speed, flowrate, flow pressure, etc.). The curves or tables can be arranged orconverted in various manners, such as into constant flow curves orassociated tables. For example, the curves can be arranged as aplurality of pressure (psi) versus speed (RPM or Hz) curves for discreteflow rates (e.g., flow curves for the range of 15 GPM to 130 GPM in 1GPM increments) and stored in the computer program memory. Thus, for agiven flow rate, one can use a known value, such as the motor speed todetermine (e.g., calculate or look-up) the flow pressure. The pumpcurves can have the data arranged to fit various mathematical models,such as linear or polynomial equations, that can be used to determinethe performance value.

In another example, the flow pressure can be determined from ameasurement of power consumption of the motor 24, 124 and/or associatedother performance values (e.g., relative amount of change, comparison ofchanged values, time elapsed, number of consecutive changes, etc.). Thechange in power consumption can be determined in various ways, such asby a change in power consumption based upon a measurement of electricalcurrent and electrical voltage provided to the motor 24, 124. Variousother factors can also be included, such as the power factor,resistance, and/or friction of the motor 24, 124 components, and/or evenphysical properties of the swimming pool, such as the temperature of thewater. It is to be appreciated that in the various implementations of a“sensorless” system, various other variables (e.g., filter loading, flowrate, flow pressure, motor speed, time, etc.) can be either supplied bya user, other system elements, and/or determined from the powerconsumption.

Keeping with the block diagram shown in FIG. 4, an example filterloading control process 300 is shown schematically. It is to beappreciated that the filter loading control process 300 can be aniterative and/or repeating process, such as a computer program or thelike. As such, the process 300 can be contained within a constantlyrepeating loop, such as a “while” loop, “if-then” loop, or the like, asis well known in the art. In one example, the “while” or “if-then” loopcan cycle at predetermined intervals, such as once every 5 minutes,though various other time cycle intervals are also contemplated.Further, it is to be appreciated that the loop can include variousmethods of breaking out of the loop due to various conditions and/oruser inputs. In one example, the loop can be broken (and the programrestarted) if a user changes an input value or a blockage or other alarmcondition is detected in the fluid circuit.

Thus, the process 300 can be initiated with step 302 and proceeds tostep 304. At step 304 information can be retrieved from a filter menu,such as through the user interface 31, 131. The information may take avariety of forms and may have a variety of contents. As one example, theinformation can include a value indicative of a clogged filter (CFP)that inhibits movement of water through the filter arrangement. Thevalue indicative of a clogged filter (CFP) can also be referred to as athreshold value, and can include an absolute value, a relative change ofa performance value (AP) with respect to a load value indicative of anunclogged filter (OP), and/or a percentage change of a performance value(AP) with respect to the load value indicative of an unclogged filter(OP). Thus, the value indicative of a clogged filter (CFP) can beentered by a user directly, such as in pounds per square inch (PSI), orcan be entered indirectly as a value, such as a value between 1 and 128.For example, a clogged filter value input of 10 psi can indicate,relative to a baseline value, such as the load value indicative of anunclogged filter (OP), a clogged filter condition. Alternatively, thevalue indicative of a clogged filter (CFP) can be calculated orotherwise determined by the controller 30, 130, such as by a look-uptable or a constant value retrieved from memory. As another example, theinformation can include the value indicative of an unclogged filter (OP)that permits movement of water through the filter arrangement. It shouldbe appreciated that such information (e.g., values) is desired and/orintended, and/or preselected/predetermined.

Subsequent to step 304, the process 300 proceeds to step 306. At step306, the process 300 can determine whether a predetermined flowreference has been reached by the pumping system 10, 110. As statedpreviously, the process 300 can act to maintain the predetermined waterflow rate despite an increase in filter loading caused by the filterarrangement becoming clogged over time. Additionally, once a steadystate flow condition has been reached (e.g., the pumping system 10, 110maintains the reference flow rate), the controller 30, 130 can use thesteady state flow rate and corresponding motor speed to determine theflow pressure, as described previously herein. Thus, the process canwait until the flow reference has been reached until beginning tomonitor the filter loading. Accordingly, if the controller 30, 130 findsthat the predetermined water flow rate has not yet been achieved by thepumping system 10, 110 (e.g., FALSE), the process 300 can proceeddirectly to step 308 to exit the filter loading process 300 until thenext time cycle (e.g., the next five minute time cycle). Alternatively,if the predetermined water flow rate has actually been achieved (e.g.,TRUE), the process 300 can proceed onto step 310.

At step 310, the process 300 can determine whether the present timecycle includes the first steady-state condition of the pumping system10, 110 that immediately follows a cleaning cycle for the filterarrangement. In one example, a steady-state condition can include astable (e.g., not transient) maintenance of the predetermined flow rateof step 306 by the pumping system 10, 110. Thus, step 310 can determinewhether the present time cycle includes the first steady-state conditionof the pumping system 10, 110 that immediately follows a backwashoperation. If step 310 determines that the present time cycle does notinclude the first steady-state condition (e.g., FALSE), the process 300can proceed onto step 314.

However, if step 310 determines that the present time cycle doesactually include the first steady-state condition of the pumping system10, 110 following a cleaning cycle (e.g., TRUE), the process 300 canproceed onto step 312. At step 312, the process 300 can determine (e.g.,calculate, measure, etc.) a value indicative of an unclogged filter,which can also be referred to as an offset value. Thus, the offset valuecan correspond to a condition of substantially no filter loading (e.g.,0%), as shown in items 206 and 208 of FIG. 3. In one example, the offsetvalue can include the water flow pressure through the clean filterarrangement and can be referred to as an offset pressure (OP). It is tobe appreciated that, because a clean filter can often have some flowpressure associated with the water being moved and filteredtherethrough, it can be beneficial to know this baseline offset pressure(OP) value. However, the offset value can also be otherwise determinedby the controller 30, 130, such as by being retrieved from memory oreven from a user input in step 304.

Subsequent to either of steps 310 or 312, the process can proceed ontostep 314. At step 314, the process 300 can determine (e.g., calculate,measure, compare, etc.) a performance value of the pumping system 10,110 during the filtration operation, such as flow pressure value of thewater being moved through the filter arrangement. The flow pressurevalue can also be referred to as an actual pressure (AP) of the pumpingsystem 10, 110. The actual pressure value (AP) can be determined invarious manners, such as by a pressure sensor. Alternatively, asdescribed previously, in a “sensorless” system the flow pressure can bedetermined directly or indirectly from a constant flow curve (e.g.,motor speed vs. pressure), measurement of power consumption of the motor24, 124, and/or even from associated other performance values (e.g.,motor speed, flow rate, time, filter loading, relative amount of change,comparison of changed values, time elapsed, number of consecutivechanges, etc.). The power consumption can be determined in various ways,such as by a measurement of electrical current and electrical voltageprovided to the motor 24, 124. In addition or alternatively, theperformance value can include various other values, such as motor speed,flow rate, or the like that can be used to indirectly determine thefilter loading.

Subsequent to step 314, the process can proceed onto step 316 todetermine a relative loading value of the filter arrangement. Therelative loading value of the filter arrangement can be based upon thevalue indicative of an unclogged filter, the value indicative of aclogged filter, and the performance value. Thus, in one example, therelative filter loading value can be based upon the offset pressure(OP), the user input clogged filter value (CFP), and the actual pressurevalue (AP) of the filter arrangement. The relative filter loading valuecan be determined in various manners. In one example, the relativefilter loading value can be calculated as a percentage directly from theoffset pressure (OP), clogged filter value (CFP), and the actualpressure value (AP). For example, the relative filter loading valuepercentage can be determined through the formula 100*((AP−OP)/(CFP−OP)).Thus, using this formula, if the offset pressure (OP) is equal to 10psi, the clogged filter value (CFP) is 20 psi, and the actual pressure(AP) is equal to 15 psi, the relative filter loading is equal to 50%.

In another example, the relative filter loading value can be calculatedfrom a chart or graph similar to that shown in FIG. 3, or even fromanother mathematical equation, chart, or graph. Other comparisonsbetween any or all of the offset pressure (OP), clogged filter value(CFP) and/or actual pressure value (AP) can also be used, and can eveninclude various other values (e.g., time, power, flow, motor speed,etc.). It is to be appreciated that the determination of any or all ofthe values (e.g., AP, OP, CFP, relative loading value) can be exact orestimated values, and that the process 300 can operate effectively witheither or both.

Subsequent to the determination of the relative loading value for thefilter arrangement, the process 300 can proceed onto step 318. At step318, the process 300 can perform various actions in response to therelative loading value. In one example, step 318 can make adetermination as to whether the relative filter loading value exceeds apredetermined or threshold value. In another example, the process 300can determine a relative change of the actual pressure (AP) value withrespect to a load value indicative of an unclogged filter (OP), and/or apercentage change of the actual pressure (AP) value with respect to theload value indicative of an unclogged filter (OP). In still yet anotherexample, the process 300 can determine a relative and/or percentagechange in the actual pressure (AP) value with respect to a previousmeasurement taken during a previous time cycle interval.

In the shown example, step 318 can determine whether the calculatedrelative filter loading percentage exceeds 100%. If the relative filterloading percentage does not exceed 100% (e.g., FALSE), the process canproceed onto step 320. At step 320, the process 300 can display therelative loading value for viewing by a user. The pumping system 10, 110can include various types of displays that may or may not beincorporated into the user interface 31, 131. In one example, thepumping system 10, 110 can include a liquid crystal display (LCD) or thelike that is configured to display the relative loading value in analphanumeric manner (e.g., “Filter Loading is 58%”) or the like. The LCDdisplay can also be configured to display various other information,such as the clogged filter pressure (CFP), offset pressure (OP), and/orthe actual pressure (AP). In another example, the pumping system 10, 110can include one or more visual indicators, such as one or more LEDlights and/or adjacent indicia corresponding to various relative loadingvalues.

Subsequent to step 320, the process 300 can proceed onto step 322. Atstep 322, the process 300 can determine whether the present water flowrate through the pumping system is equal to the original reference flowrate. If the present water flow rate does not equal the reference flowrate (e.g., FALSE), the process 300 can proceed onto step 324 to controlthe motor in response to the relative loading value, such as may berequired if the filter is partially loaded. For example, as shown instep 324, the process 300 can increase the flow rate by one gallon perminute (GPM), though the process 300 can make other corrections asneeded.

If the present water flow rate does equal the reference flow rate (e.g.,TRUE), or if the process has already performed step 324, the process 300can then proceed onto step 308 to exit the filter loading process 300.Because the filter loading process 300 is a repetitious program, it canrepeat at a predetermined interval, such as once every five minutes,though various other time intervals are contemplated to be within thescope of the invention. It can be beneficial for the time cycleintervals to have an appreciable length as it can often take a fewmonths for a general pool filter to reach a clogged condition. However,in situations where a filter is prone to clog easily or quickly, thetime cycle interval can be reduced accordingly.

Turning back to step 318, if the relative filter loading percentage doesexceed 100% (e.g., TRUE), then the process can proceed onto step 326. Atstep 326, the process 300 can indicate a 100% or greater filter loadingcondition, and can also display various alarms. In one example, the LCDdisplay could display a warning message, such as “Service System Soon.”In addition or alternatively, various other indicators and/or warningscan also be used to alert a user, such as various other lights and/orsounds (e.g., beepers, buzzers or the like).

Subsequent to step 326, the process 300 can proceed onto step 328 tocontrol the motor in response to the relative loading value, such as maybe required if the filter is in a clogged condition. For example, asshown in step 328, the process 300 can decrease the flow rate by onegallon per minute (GPM), though the process 300 can make othercorrections as needed. By decreasing the flow rate by one GPM, theactual pressure (AP) of the water flow through the filter arrangementcan also decrease. The process 300 can continue to decrease the flowrate during each consecutive time cycle until the relative loading valueis less than 100% to help prolong the filter life. In addition oralternatively, the process 300 can continue to decrease the flow rateduring each consecutive time cycle until a backwash cycle has beencompleted to clean the filter arrangement. In addition or alternatively,the process 300 can make other adjustments. For example, the process 300can automatically initiate a backwash cycle to clean the filterarrangement, or it can even shut down the pumping system 10, 110 until auser manually restarts it. Subsequent to step 328, the process 300 canthen proceed onto step 308 to exit the filter loading process 300,whereupon the process 300 can repeat at the predetermined interval asdiscussed above.

Further still, in accordance with yet another aspect of the invention, amethod of moving water of a swimming pool in connection with performanceof a filtering operation upon the water is provided. The method caninclude some or all of the aforementioned features of the filter loadingcontrol process 300, though more or less steps can also be included toaccommodate the various other features described herein. One examplemethod of moving water of a swimming pool can be used with a water pumpfor moving water in connection with performance of a filtering operationupon the water, a variable speed motor operatively connected to drivethe pump, and a filter arrangement in fluid communication with the pump.The method can comprise the steps of determining a flow pressure valueindicative of an unclogged filter that permits movement of water throughthe filter arrangement, determining a threshold flow pressure valueindicative of a clogged filter that inhibits movement of water throughthe filter arrangement, and determining an actual pressure value of thepumping system during the filtering operation. The method can alsoinclude the steps of determining a relative loading value of the filterarrangement based upon the pressure value indicative of an uncloggedfilter, pressure value indicative of a clogged filter, and the actualpressure value, displaying the relative loading value, and controllingthe motor in response to the relative loading value.

It is to be appreciated that the controller (e.g., 30 or 130) may havevarious forms to accomplish the desired functions. In one example, thecontroller 30 includes a computer processor that operates a program. Inthe alternative, the program may be considered to be an algorithm. Theprogram may be in the form of macros. Further, the program may bechangeable, and the controller 30 is thus programmable.

Also, it is to be appreciated that the physical appearance of thecomponents of the system (e.g., 10 or 110) may vary. As some examples ofthe components, attention is directed to FIGS. 5-7. FIG. 5 is aperspective view of the pump unit 112 and the controller 130 for thesystem 110 shown in FIG. 2. FIG. 6 is an exploded perspective view ofsome of the components of the pump unit 112. FIG. 7 is a perspectiveview of the controller 130.

It should be evident that this disclosure is by way of example and thatvarious changes may be made by adding, modifying or eliminating detailswithout departing from the scope of the teaching contained in thisdisclosure. As such it is to be appreciated that the person of ordinaryskill in the art will perceive changes, modifications, and improvementsto the example disclosed herein. Such changes, modifications, andimprovements are intended to be within the scope of the presentinvention.

The invention claimed is:
 1. A pumping system for a swimming pool, thepumping system comprising: a pump; a motor coupled to the pump; a filtercoupled to the pump; and a controller in communication with the motor,the controller determining if a steady state flow rate to achieve adesired number of turnovers in the swimming pool has been reached, thecontroller calculating a filter loading value based on a clogged filterpressure value, an unclogged filter pressure value, and an actualpressure of the pumping system after the steady state flow rate has beenreached, the controller decreasing an actual flow rate of the pumpingsystem if the filter loading value is greater than a threshold value tohelp prolong filter life after the filter has become clogged, thecontroller decreasing the actual flow rate during at least onesubsequent time cycle until at least one of the filter loading value isless than the threshold value and a backwash cycle is completed, thecontroller increasing the actual flow rate if the filter loading valueis less than the threshold value and the actual flow rate is less thanthe steady state flow rate.
 2. The pumping system of claim 1, whereinthe controller attempts to maintain the steady state flow rate despitean increase in the filter loading value caused by the filter becomingclogged.
 3. The pumping system of claim 1, wherein the clogged filterpressure value includes at least one of an absolute value, a relativechange with respect to the unclogged filter pressure value, and apercentage change with respect to the unclogged filter pressure value.4. The pumping system of claim 1, wherein the controller determineswhether the steady state flow rate substantially immediately follows abackwash operation.
 5. The pumping system of claim 4, wherein thecontroller determines the unclogged filter pressure value after thebackwash operation.
 6. The pumping system of claim 1, wherein thecontroller uses a motor speed to determine the actual pressure.
 7. Thepumping system of claim 6, wherein the controller uses a curve of motorspeed versus pressure to determine the actual pressure.
 8. The pumpingsystem of claim 1, wherein the controller uses power consumption of themotor to determine the actual pressure.
 9. The pumping system of claim8, wherein the controller determines the power consumption of the motorfrom at least one of current and voltage provided to the motor.
 10. Thepumping system of claim 1, wherein the filter loading value is apercentage calculated from the clogged filter pressure value, theunclogged filter pressure value, and the actual pressure, and whereinthe threshold value is about 100 percent.
 11. The pumping system ofclaim 1, wherein the controller determines whether the filter loadingvalue has exceeded the threshold value by determining at least one of arelative change and a percentage change in the actual pressure withrespect to a load angle of an unclogged filter.
 12. The pumping systemof claim 11, wherein the controller determines at least one of therelative change and the percentage change with respect to a previousmeasurement taken during a previous time cycle interval.
 13. The pumpingsystem of claim 1, wherein the controller displays the filter loadingvalue.
 14. The pumping system of claim 13, wherein the controllerdisplays a service system soon indicator when the filter loading valueis greater than the threshold value.
 15. The pumping system of claim 1,wherein the controller increases the actual flow rate by about onegallon per minute in order to attempt to maintain the steady state flowrate.
 16. The pumping system of claim 1, wherein the controllerdecreases the actual flow rate by about one gallon per minute in orderto lower the filter loading value.
 17. The pumping system of claim 16,wherein the controller decreases the actual flow rate during eachconsecutive time cycle of a predetermined elapsed period of time untilat least one of the filter loading value is less than the thresholdvalue and a backwash cycle is completed.
 18. The pumping system of claim1, wherein the controller determines the filter loading value about onceevery five minutes.
 19. The pumping system of claim 1, wherein thecontroller automatically initiates a backwash cycle when the filterloading value is greater than the threshold value.
 20. The pumpingsystem of claim 1, wherein the controller automatically shuts down thepumping system when the filter loading value is greater than thethreshold value and the pumping system remains shut down until thepumping system is manually restarted.
 21. The pumping system of claim 1,wherein the filter includes at least one of a sand filter, a cartridgefilter, and a diatomaceous earth filter.
 22. The pumping system of claim1, wherein the actual flow rate of the pumping system depends in part onthe desired number of turnovers.